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Inspection/Measurement 22 MoldMaking Technology November 2014 An automated work cell incorporates a shop-foor CMM to verify electrode and workpiece offsets before delivering them to the sinking machine. Zero Failure Rates CMM technology can also be an asset to moldmakers during the design process. Certain products need to be designed to tighter tolerances due to their potential liability. For instance, a part that serves as an enclosure for liquids will need to meet strict tolerances so the enclosure does not fail and the liquid does not escape. A 5-gallon bucket, though a relatively simple part, may be used to hold bleach or paint that could do seri- ous damage if it leaks. Finding the point where the product is secure, without investing resources and material in an over- engineered design, is a perfect application of metrology. Metrology is the Key When traditional hand measurement tools such as calipers and micrometers are used to inspect a part's features, the validity of the results is highly dependent on the operator's skill level. Measurement inaccuracies due to operator error are virtually eliminated with today's advanced metrology equip- CONTRIBUTORS Jonathan Dove is a systems engineer for Hexagon Metrology. ment, such as CMMs (including portable-arm CMMs), stereovi- sion and laser scanners. With this technology, inspections can occur in a fraction of the time compared with manual meth- ods. These tools also provide the accuracy required to meet tight tolerances needed to con- trol material and tooling costs, as well as diminish product failure rates. Manual inspection methods may also restrict the inspection of complex 3D sur- faces with hidden features. Metrology equipment can expand the automation potential for moldmakers. For exam- ple, an automated work cell can include a shopfloor CMM for electrode verification and workpiece positioning. Here inspec- tion is the secondary function of the cell's CMM. The process begins as a palletized workpiece or electrode is picked up by a robot from the machining center. After dirt and lubricant removal, the robot moves the part to the CMM for evaluation of the X, Y, Z and C (rotation in the X-Y plane) offsets, as well as necessary compensation for spark gaps. Adjustments are then made in the software, as the component is automatically delivered to a sinker EDM. When complete, the workpiece is returned to the CMM. Big Rewards While there will be growing pains, implementation of metrol- ogy technology promises big rewards for the moldmaking industry. As innovations in machining technology continue to enable greater precision and tighter tolerances, the industry must introduce necessary tools such as automated CMMs to ensure better results. In the short-term, companies new to metrology technology will shoulder a learning curve and investment in capital equip- ment. The long-term benefits, however, will be cost savings that translate into rapid return on investment, as increased accuracy aids their manufacturing processes. These cost benefits are realized in the form of time saved, lower material and tool- ing costs, and a move to zero failure rates of finished goods. FOR MORE INFORMATION: Hexagon Metrology / 855-443-9638 jonathan.dove@hexagonmetrology.com / hexagonmetrology.us Metrology software allows for seamless extraction of features from the point cloud generated by laser scanning.